Tennant CS16 Operating manual

PLDC04626

REVISION DATE

March 11, 2022

TECHNICAL OFFICE

TECHNICAL SERVICE MANUAL

Stavale

CS16

DATE

March 11, 2022

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PLDC04626

REVISION 00

March 11, 2022

TECHNICAL OFFICE

Stavale

ALARM CODES DISPLAYED

Error: BRUSH SHUTDOWN

On display: 2 quick flashes of brush LED ref. 3

Short-circuit protection error.

This occurs when excessive peak current is detected.

Check that the brush motor wiring is not short-circuited.

Manually check that the brush motor rotates freely and without effort.

Error: SUCTION SHUTDOWN

On display: 2 fast flashes of suction LED ref. 4

Short-circuit protection error.

This occurs when excessive peak current is detected.

Check that the suction motor wiring is not short-circuited.

Manually check that the suction motor rotates freely and without effort.

234 5

Error: BRUSH I²T

On display: 2 slow flashes of brush LED ref. 3

Brush motor overload error.

Check that the brushes and the drive are not rubbing anywhere.

Check brush motor current draw.

Error: SUCTION I²T

On display: 2 slow flashes of suction LED ref. 4

Suction motor overload error.

Check check that the suction motor rotor rotates freely.

Check brush motor current draw.

Error: MAXIMUM TEMPERATURE

On display: fast, continuous flashing of brush LED ref. 3 and suction LED ref. 4 simultaneously.

Power board overheating error.

To restore the functions switch the machine off and wait around 15 minutes until the power board

cools down.

Check brush motor and suction motor current draw.

Error: BRUSH THERMAL PROTECTOR

On display: 4 consecutive flashes of brush LED ref. 3.

Brush motor overheating error.

Brush motor thermal protector tripped

The board cuts off power to the brush motor.

Wait for the brush motor to cool down and the thermal protector inside the motor to reset.

Warning: BATTERIES CHARGED

On display: 5 consecutive flashes of yellow battery LED ref. 1.

Charged batteries warning.

Disconnect the battery charger.

Warning: BATTERIES DISCHARGED

On display: 6 consecutive flashes of yellow battery LED ref. 1.

Discharged batteries warning.

Recharge the batteries.

Error: BRUSH MOTOR SHUTDOWN

On display: 11 consecutive flashes of yellow battery LED ref. 1.

Brush motor shut down by power board, due to discharged battery with

voltage at minimum set threshold of 21.9 Volts.

Recharge the batteries.

Error: SUCTION MOTOR SHUTDOWN

On display: 12 consecutive flashes of yellow battery LED ref. 1.

Brush motor shut down by power board, due to discharged battery with voltage at minimum safety

threshold of 21.5 Volts.

Recharge the batteries.

Warning: BATTERY CHARGER ON

On display: 7 consecutive flashes of yellow battery LED ref. 1.

Batteries charging warning.

Wait until batteries are fully recharged.

Information - I²T:

The overload error (I²T)is shown when the power board needs to deliver current that exceeds the set

maximum value.

ctivation of the power board shuts down the motor that caused the error, and is signalled by the

flashing of the LED on the instrument panel corresponding to the motor in question.

For the suction motor, the limit is 30 Amperes (exceeding 30A) for a maximum of 20 seconds.

For the brush motor, the limit is 15 Amperes (exceeding 15A) for a maximum of 20 seconds.

The problem can be reset by switching the machine off and on again. If the error occurs again, check the

Information - MAXIMUM TEMPERATURE ERROR:

The overheating error on the brush motor and suction motor power board is shown when the board

temperature exceeds the maximum set value.

ctivation of the power board shuts down both motors, regardless of which caused the overheating, and

is signalled by fast and continuous flashing of the LEDs corresponding to both the brush and suction

motor.

Information - SUCTION IN REMOTE MODE:

Can be activated starting from serial number 8000209102

Pressing the suction button ref. 4 for around 5 seconds, the suction motor will start without acting on the

brush control lever.

Information - ERRORS NOT DISPLAYED:

If the machine fails to start or the functions cannot be activated, without any errors shown on the display,

the problem could be due to a broken flat cable, a damaged display board or a short-circuit on the power

board.

In these cases to restore normal operation, replace the faulty component (flat cable, display board,

power board), which can be identified by inspecting the component visually, or replacing them one-by-

Information - SHUTDOWN ERROR:

If activated due to "short circuit" or "excessive peak current" detected by the power board, the problem

may involve the brush and/or suction motor wiring or motor power supply or the actual power board

itself.

In the shutdown error involves the motors or the motor wiring, the electronic control board stops the

function and signals the error via the LED on the instrument panel.

Sub

ect Page

ABRUSH HEAD

A1 MEASURING BRUSH MOTOR CURRENT DRAW 2

A1.1 Measuring brush motor current draw on the CS16 Battery 3

A1.2 Replacing the brush motor’s carbon brushes on the CS16 Battery 5

A1.3 Replacing the brush motor’s carbon brushes on the CS16 Cord 9

A2 REMOVING THE BRUSH MOTOR - BRUSH HEAD 13

A2.1 Removing the brush motor from the CS16 Battery 14

A2,2 Removing the brush motor from the CS16 Cord 18

A2.3 Removing the brush head from the CS16 B and CS16 Cord 19

A2.4 Replacing the brush motor’s thermal protector 21

BSUCTION UNIT - TANKS

B1 SUCTION MOTOR 25

B1.1 Measuring suction motor current draw on the CS16 Battery 26

B1.2 Removing the suction motor from the CS16 Battery 28

B1.3 Replacing the suction motor carbon brushes on the CS16 Battery 30

B1.4 Removing the suction motor from the CS16 Cord 32

B1.5 Replacing the suction motor carbon brushes on the CS16 Cord 33

B2 SQUEEGEE UNIT 35

B2.1 Adjusting the squeegee 36

B2.2 Replacing the squeegee flaps 37

B3 CLEANING FILTERS AND HOSES - TESTING THE SOLENOID VALVE AND FLOAT 41

B3.1 Testing the solenoid valve 42

B3.2 Testing and replacing the solenoid valve on “B” version machines 44

B3.3 Checking the condition of the float 48

B3.4 Cleaning the filters, hoses and solution dispensing cock 49

DINSTRUMENT PANEL/POWER BOARD-BATTERY CHARGER-ELECTRICAL CIRCUIT

D1 INSTRUMENT PANEL BOARD - POWER BOARD 55

D1.1 Replacing the function control card on “B” and “C” version machines 56

D1.2 Testing the function control card on “B” and “C” version machines 59

D1.3 Replacing the power board on “Battery” version machines 62

D1.4 Testing the power control card on “Battery” version machines 66

D1.5 Replacing the power control card on Cord type machines 69

D1.6 Testing the power control card on Cord type machines 73

D2 BATTERY CHARGER 82

D2.1 Replacing the battery charger 83

D2.2 Setting the battery charger charging curve 88

D3 WIRING DIAGRAMS 96

D3.1 Electric wiring diagram for type Battery versions 96

D3.2 Electric wiring diagram for type Cord versions 97

EERROR CODES - TROUBLESHOOTING

E1 DISPLAY OF ERROR CODES 99

E1.1 Error codes for the fuction control card on Battery type machines 99

E2 TROUBLESHOOTING 105

E2.1 Troubleshooting 105

REVISIONS - UPDATES 109

OPTIONS

INDEX

PLDC04626

REVISION 00

March 11, 2022

TECHNICAL OFFICE

Stavale

In line with the company's policy of constant product development and updating,

the Manufacturer reserves the right to make modifications without warning.

Although your machine may differ appreciably from the illustrations in this document,

safety and the information contained in this manual are guaranteed.

WARNINGS

! DANGER

could cause damage to the machine or work environment or financial loss.

i INFORMATION

Indicates particularly important instructions.

Indicates the need for attention in order to avoid a series of consequences which

could cause death or damage to the health of the operator.

WARNING

Indicates the need for attention in order to avoid a series of consequences which

PLDC04626

REVISION 00

March 11, 2022

TECHNICAL DEPT.

Stavale

March 11, 2022 1/109

A BRUSH HEAD

WARNING!

Go to the designated draining area and empty the

solution and collection tanks using the drain plugs

and the hoses provided.

Position the machine on a flat floor, and place wedges

under the wheels to stop it moving.

Switch the machine off and disable all functions by

pressing the “On–Off” button on the control panel.

Disconnect the machine’s electrical system by removing

the main fuse F1, or by disconnecting the terminals

from the battery poles (battery powered machines),

or by removing the plug from the mains power socket

(mains powered machines).

i INFORMATION

Important information

In this Service Manual, the terms RIGHT and LEFT are

used to indicate the sides of the machine. They

always refer to the direction of travel.

In this Service Manual, the machine version (CS16 B

= battery, CS16 C = corded)may appear between

brackets “( )”. This indicates that the instruction in

question refers only to the version specified.

PLDC04626

REVISION 00

March 11, 2022

TECHNICAL DEPT.

Stavale

March 11, 2022 2/109

A1 MEASURING BRUSH MOTOR CURRENT DRAW

On the scrubber CS16, the brush motors of type battery versions and cord type

versions are very similar. Apart from the power source (24 V DC for battery versions

and 230V AC for “C” versions), the differences lie in the motors’ maximum current

draw and in the type of connections. The motors of mains powered versions feature

waterproof terminals to provide increased protection against electric shock.

CS16 Battery CS16 Cord

PHOTO 1

PLDC04626

REVISION 00

March 11, 2022

TECHNICAL DEPT.

Stavale

March 11, 2022 3/109

A1.1 Measuring brush motor current draw on the CS16 Battery

1Make sure that the batteries on the machine are fully charged (24V ± 1V).

2Use a clamp-on ammeter with a full scale reading of at least 200 A (amperes) as shown below.

3Move the machine to the tank draining area, and completely empty the collection tank A.

4Make sure that the solution tank contains only a small amount of solution before you start.

5Move the machine to a flat, dry and smooth floor.

6Make sure that you have enough room around the machine to perform the measurement safely.

7Unhook the hoses and lift up and remove the collection tank Ato access the cables B of the brush motor.

8Set the clamp-on ammeter to measure amperes (A) of DC current, and clamp it to the red cable.

9Press the “On-Off” button to switch the machine on, and press button Cto switch off suction.

10 Pull in the control lever Don the handle. Read and record the current draw of the brush motor.

PHOTO 2

PHOTO 3

PHOTO 4

25A

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